US5213160A - Method for conversion of oil-base mud to oil mud-cement - Google Patents
Method for conversion of oil-base mud to oil mud-cement Download PDFInfo
- Publication number
- US5213160A US5213160A US07/961,217 US96121792A US5213160A US 5213160 A US5213160 A US 5213160A US 96121792 A US96121792 A US 96121792A US 5213160 A US5213160 A US 5213160A
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- US
- United States
- Prior art keywords
- oil
- mud
- cement
- water
- slurry
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- 238000000034 method Methods 0.000 title claims abstract description 26
- 239000004568 cement Substances 0.000 title abstract description 150
- 238000006243 chemical reaction Methods 0.000 title description 4
- 239000002002 slurry Substances 0.000 claims abstract description 57
- 238000005553 drilling Methods 0.000 claims abstract description 38
- 239000000463 material Substances 0.000 claims abstract description 14
- 239000007762 w/o emulsion Substances 0.000 claims abstract 3
- 239000003921 oil Substances 0.000 claims description 116
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 98
- 239000000203 mixture Substances 0.000 claims description 19
- 239000003995 emulsifying agent Substances 0.000 claims description 17
- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical compound [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 claims description 11
- IBZGBXXTIGCACK-UHFFFAOYSA-N 6,7,9,11-tetrahydroxy-9-(2-hydroxyacetyl)-4-methoxy-8,10-dihydro-7h-tetracene-5,12-dione Chemical compound C1C(O)(C(=O)CO)CC(O)C2=C1C(O)=C1C(=O)C(C=CC=C3OC)=C3C(=O)C1=C2O IBZGBXXTIGCACK-UHFFFAOYSA-N 0.000 claims description 9
- 235000002639 sodium chloride Nutrition 0.000 claims description 9
- 239000011398 Portland cement Substances 0.000 claims description 8
- 239000003784 tall oil Substances 0.000 claims description 6
- 239000011780 sodium chloride Substances 0.000 claims description 5
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims description 4
- WCUXLLCKKVVCTQ-UHFFFAOYSA-M Potassium chloride Chemical compound [Cl-].[K+] WCUXLLCKKVVCTQ-UHFFFAOYSA-M 0.000 claims description 4
- 239000011777 magnesium Substances 0.000 claims description 4
- 229910052749 magnesium Inorganic materials 0.000 claims description 4
- 150000003839 salts Chemical class 0.000 claims description 4
- VWDWKYIASSYTQR-UHFFFAOYSA-N sodium nitrate Chemical compound [Na+].[O-][N+]([O-])=O VWDWKYIASSYTQR-UHFFFAOYSA-N 0.000 claims description 4
- JIAARYAFYJHUJI-UHFFFAOYSA-L zinc dichloride Chemical compound [Cl-].[Cl-].[Zn+2] JIAARYAFYJHUJI-UHFFFAOYSA-L 0.000 claims description 4
- 239000004952 Polyamide Substances 0.000 claims description 3
- 235000014113 dietary fatty acids Nutrition 0.000 claims description 3
- 239000000194 fatty acid Substances 0.000 claims description 3
- 229930195729 fatty acid Natural products 0.000 claims description 3
- 150000004665 fatty acids Chemical class 0.000 claims description 3
- 229920002647 polyamide Polymers 0.000 claims description 3
- BFNBIHQBYMNNAN-UHFFFAOYSA-N ammonium sulfate Chemical compound N.N.OS(O)(=O)=O BFNBIHQBYMNNAN-UHFFFAOYSA-N 0.000 claims description 2
- 229910052921 ammonium sulfate Inorganic materials 0.000 claims description 2
- 235000011130 ammonium sulphate Nutrition 0.000 claims description 2
- 239000010881 fly ash Substances 0.000 claims description 2
- 239000001103 potassium chloride Substances 0.000 claims description 2
- 235000011164 potassium chloride Nutrition 0.000 claims description 2
- 239000002893 slag Substances 0.000 claims description 2
- 239000004317 sodium nitrate Substances 0.000 claims description 2
- 235000010344 sodium nitrate Nutrition 0.000 claims description 2
- 239000011592 zinc chloride Substances 0.000 claims description 2
- 235000005074 zinc chloride Nutrition 0.000 claims description 2
- PUZPDOWCWNUUKD-UHFFFAOYSA-M sodium fluoride Chemical compound [F-].[Na+] PUZPDOWCWNUUKD-UHFFFAOYSA-M 0.000 claims 2
- PAYRUJLWNCNPSJ-UHFFFAOYSA-N N-phenyl amine Natural products NC1=CC=CC=C1 PAYRUJLWNCNPSJ-UHFFFAOYSA-N 0.000 claims 1
- 229910002651 NO3 Inorganic materials 0.000 claims 1
- 239000004115 Sodium Silicate Substances 0.000 claims 1
- 150000001298 alcohols Chemical class 0.000 claims 1
- KWKXNDCHNDYVRT-UHFFFAOYSA-N dodecylbenzene Chemical group CCCCCCCCCCCCC1=CC=CC=C1 KWKXNDCHNDYVRT-UHFFFAOYSA-N 0.000 claims 1
- NHNBFGGVMKEFGY-UHFFFAOYSA-N nitrate group Chemical group [N+](=O)([O-])[O-] NHNBFGGVMKEFGY-UHFFFAOYSA-N 0.000 claims 1
- 150000007524 organic acids Chemical class 0.000 claims 1
- 235000005985 organic acids Nutrition 0.000 claims 1
- 239000011734 sodium Substances 0.000 claims 1
- 229910052708 sodium Inorganic materials 0.000 claims 1
- 235000013024 sodium fluoride Nutrition 0.000 claims 1
- 239000011775 sodium fluoride Substances 0.000 claims 1
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims 1
- 229910052911 sodium silicate Inorganic materials 0.000 claims 1
- BDHFUVZGWQCTTF-UHFFFAOYSA-M sulfonate Chemical compound [O-]S(=O)=O BDHFUVZGWQCTTF-UHFFFAOYSA-M 0.000 claims 1
- 239000002699 waste material Substances 0.000 claims 1
- 239000012530 fluid Substances 0.000 abstract description 36
- 239000012065 filter cake Substances 0.000 abstract description 20
- 230000015572 biosynthetic process Effects 0.000 abstract description 11
- 239000003129 oil well Substances 0.000 abstract description 2
- 230000001960 triggered effect Effects 0.000 abstract 1
- 239000002585 base Substances 0.000 description 48
- 238000012360 testing method Methods 0.000 description 42
- 238000006703 hydration reaction Methods 0.000 description 22
- 230000036571 hydration Effects 0.000 description 17
- 239000007787 solid Substances 0.000 description 13
- 239000002245 particle Substances 0.000 description 11
- 230000000694 effects Effects 0.000 description 10
- 238000005755 formation reaction Methods 0.000 description 10
- 238000006073 displacement reaction Methods 0.000 description 9
- 239000000654 additive Substances 0.000 description 8
- 238000002955 isolation Methods 0.000 description 8
- 238000007792 addition Methods 0.000 description 7
- 238000002156 mixing Methods 0.000 description 7
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 6
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 6
- 238000007711 solidification Methods 0.000 description 6
- 230000008023 solidification Effects 0.000 description 6
- 239000003381 stabilizer Substances 0.000 description 6
- 230000003068 static effect Effects 0.000 description 6
- 239000000080 wetting agent Substances 0.000 description 6
- UXVMQQNJUSDDNG-UHFFFAOYSA-L Calcium chloride Chemical compound [Cl-].[Cl-].[Ca+2] UXVMQQNJUSDDNG-UHFFFAOYSA-L 0.000 description 5
- 239000012267 brine Substances 0.000 description 5
- 239000001110 calcium chloride Substances 0.000 description 5
- 229910001628 calcium chloride Inorganic materials 0.000 description 5
- 239000000839 emulsion Substances 0.000 description 5
- 238000001914 filtration Methods 0.000 description 5
- 230000035699 permeability Effects 0.000 description 5
- 230000008569 process Effects 0.000 description 5
- HPALAKNZSZLMCH-UHFFFAOYSA-M sodium;chloride;hydrate Chemical compound O.[Na+].[Cl-] HPALAKNZSZLMCH-UHFFFAOYSA-M 0.000 description 5
- 239000003795 chemical substances by application Substances 0.000 description 4
- 239000013078 crystal Substances 0.000 description 4
- 239000002283 diesel fuel Substances 0.000 description 4
- 238000011065 in-situ storage Methods 0.000 description 4
- BDAGIHXWWSANSR-UHFFFAOYSA-N methanoic acid Natural products OC=O BDAGIHXWWSANSR-UHFFFAOYSA-N 0.000 description 4
- 230000001133 acceleration Effects 0.000 description 3
- 230000000996 additive effect Effects 0.000 description 3
- 230000032683 aging Effects 0.000 description 3
- HPXRVTGHNJAIIH-UHFFFAOYSA-N cyclohexanol Chemical compound OC1CCCCC1 HPXRVTGHNJAIIH-UHFFFAOYSA-N 0.000 description 3
- 239000013505 freshwater Substances 0.000 description 3
- 210000002445 nipple Anatomy 0.000 description 3
- 238000005086 pumping Methods 0.000 description 3
- 238000007789 sealing Methods 0.000 description 3
- 238000000926 separation method Methods 0.000 description 3
- 238000010008 shearing Methods 0.000 description 3
- 230000000153 supplemental effect Effects 0.000 description 3
- OSWFIVFLDKOXQC-UHFFFAOYSA-N 4-(3-methoxyphenyl)aniline Chemical compound COC1=CC=CC(C=2C=CC(N)=CC=2)=C1 OSWFIVFLDKOXQC-UHFFFAOYSA-N 0.000 description 2
- 235000008733 Citrus aurantifolia Nutrition 0.000 description 2
- 235000011941 Tilia x europaea Nutrition 0.000 description 2
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 description 2
- 229910052601 baryte Inorganic materials 0.000 description 2
- 239000010428 baryte Substances 0.000 description 2
- 239000002199 base oil Substances 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 239000000378 calcium silicate Substances 0.000 description 2
- 229910052918 calcium silicate Inorganic materials 0.000 description 2
- OYACROKNLOSFPA-UHFFFAOYSA-N calcium;dioxido(oxo)silane Chemical compound [Ca+2].[O-][Si]([O-])=O OYACROKNLOSFPA-UHFFFAOYSA-N 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 230000003247 decreasing effect Effects 0.000 description 2
- 230000001804 emulsifying effect Effects 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 235000019253 formic acid Nutrition 0.000 description 2
- 238000009472 formulation Methods 0.000 description 2
- 239000011521 glass Substances 0.000 description 2
- 239000004571 lime Substances 0.000 description 2
- 239000012528 membrane Substances 0.000 description 2
- 238000012544 monitoring process Methods 0.000 description 2
- 231100000252 nontoxic Toxicity 0.000 description 2
- 230000003000 nontoxic effect Effects 0.000 description 2
- 238000000518 rheometry Methods 0.000 description 2
- 238000012216 screening Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 239000003643 water by type Substances 0.000 description 2
- 239000010755 BS 2869 Class G Substances 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- XDTMQSROBMDMFD-UHFFFAOYSA-N Cyclohexane Chemical compound C1CCCCC1 XDTMQSROBMDMFD-UHFFFAOYSA-N 0.000 description 1
- SNRUBQQJIBEYMU-UHFFFAOYSA-N Dodecane Natural products CCCCCCCCCCCC SNRUBQQJIBEYMU-UHFFFAOYSA-N 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- 239000008186 active pharmaceutical agent Substances 0.000 description 1
- 229910001508 alkali metal halide Inorganic materials 0.000 description 1
- 150000008045 alkali metal halides Chemical class 0.000 description 1
- -1 amine dodecyl benzene sulfonate Chemical class 0.000 description 1
- 239000011575 calcium Substances 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 230000001143 conditioned effect Effects 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000018109 developmental process Effects 0.000 description 1
- 238000010790 dilution Methods 0.000 description 1
- 239000012895 dilution Substances 0.000 description 1
- LRCFXGAMWKDGLA-UHFFFAOYSA-N dioxosilane;hydrate Chemical compound O.O=[Si]=O LRCFXGAMWKDGLA-UHFFFAOYSA-N 0.000 description 1
- 125000003438 dodecyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])* 0.000 description 1
- 229940071161 dodecylbenzenesulfonate Drugs 0.000 description 1
- 238000004945 emulsification Methods 0.000 description 1
- 229920006333 epoxy cement Polymers 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 239000000499 gel Substances 0.000 description 1
- JEGUKCSWCFPDGT-UHFFFAOYSA-N h2o hydrate Chemical compound O.O JEGUKCSWCFPDGT-UHFFFAOYSA-N 0.000 description 1
- 150000004677 hydrates Chemical class 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 230000006698 induction Effects 0.000 description 1
- 239000003701 inert diluent Substances 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 238000009533 lab test Methods 0.000 description 1
- 229920005610 lignin Polymers 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 231100000053 low toxicity Toxicity 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 238000013508 migration Methods 0.000 description 1
- 230000005012 migration Effects 0.000 description 1
- 235000010755 mineral Nutrition 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 239000002480 mineral oil Substances 0.000 description 1
- 230000003204 osmotic effect Effects 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 230000000979 retarding effect Effects 0.000 description 1
- 238000012552 review Methods 0.000 description 1
- 239000011435 rock Substances 0.000 description 1
- 239000013535 sea water Substances 0.000 description 1
- XZPVPNZTYPUODG-UHFFFAOYSA-M sodium;chloride;dihydrate Chemical compound O.O.[Na+].[Cl-] XZPVPNZTYPUODG-UHFFFAOYSA-M 0.000 description 1
- 239000011343 solid material Substances 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 125000006850 spacer group Chemical group 0.000 description 1
- 230000000087 stabilizing effect Effects 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 239000000375 suspending agent Substances 0.000 description 1
- 229920001864 tannin Polymers 0.000 description 1
- 239000001648 tannin Substances 0.000 description 1
- 235000018553 tannin Nutrition 0.000 description 1
- 230000008719 thickening Effects 0.000 description 1
- 231100000419 toxicity Toxicity 0.000 description 1
- 230000001988 toxicity Effects 0.000 description 1
- 239000002569 water oil cream Substances 0.000 description 1
- 238000009736 wetting Methods 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B18/04—Waste materials; Refuse
- C04B18/0481—Other specific industrial waste materials not provided for elsewhere in C04B18/00
- C04B18/049—Wastes from oil or other wells, e.g. drilling mud
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
- C09K8/02—Well-drilling compositions
- C09K8/32—Non-aqueous well-drilling compositions, e.g. oil-based
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
- C09K8/42—Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells
- C09K8/46—Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells containing inorganic binders, e.g. Portland cement
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B33/00—Sealing or packing boreholes or wells
- E21B33/10—Sealing or packing boreholes or wells in the borehole
- E21B33/13—Methods or devices for cementing, for plugging holes, crevices or the like
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/91—Use of waste materials as fillers for mortars or concrete
Definitions
- the present invention pertains to improvements in compositions and methods for zonal isolation for vertical, deviated, and horizontal oil and gas wells.
- the method involves the utilization of oil-base universal fluid for providing settable filter cake while drilling and the subsequent in-situ solidification of the drilling mud or both the drilling mud and universal fluid filter cake to compressive strengths well in excess of that required for casing support, zonal isolation, and borehole stability.
- the general procedure of drilling an oil or gas well includes drilling a borehole using a drilling fluid (also termed drilling mud). Subsequent to drilling the borehole casing is run into the well and a cement slurry is then placed in the annulus between the outside of the casing and the borehole wall. In order to obtain a good cementing job, it is necessary for the cement slurry to displace substantially all of the drilling mud from the annulus. A reduced displacement efficiency arises from the geometry of the system and also from the fact that drilling fluids and cements are usually incompatible.
- Nondisplaced mud mud still left in the borehole after cementing
- mud filter cake are major causes of unsatisfactory cement performance. Since the nondisplaced mud and mud filter cake do not set or bond to the casing, the borehole wall or the set cement itself, the mud and filter cake do not support the casing properly and later can allow annular gas or fluid migration.
- oil-base muds which contain water as the internal emulsified phase.
- These oil-base muds are used, for example, to lower drilling torque and drag, reduce damage to productive formations, increase wellbore stability or reduce differential pressure pipe sticking, etc.
- the presence of oil mud in the wellbore can even further reduce the displacement efficiency while cementing with a conventional water-base cement slurry.
- the drilling industry has sought to overcome the above problems by using a variety of techniques to displace the drilling fluid with cement, e.g., turbulent flow, casing movement (reciprocation/rotation), casing equipment (centralizers, flow diverters, mud cake scratchers), and special spacers and wash fluids, but these have had limited success.
- Even greater cementing difficulties are encountered when the boreholes deviate greatly from vertical.
- Major problems arise in connection with casing placement, drilled solids settling, mud displacement, casing centralization, fluid separation (free water), and mechanical friction.
- One of the major objectives of a primary cementing is to obtain good zonal isolation in the annulus of the well. Effective zonal isolation is achieved by sealing the cement and borehole wall.
- the interface of the cement and borehole wall is usually an interface between the cement and drilling fluid filter cake which is the source of many cementing problems.
- Good zonal isolation can be achieved if the filter cake hardens, permanently bonds to the formation face and the cement, and provides hydraulic sealing.
- the present invention is directed to overcoming the above-noted problems in the art and to providing a solution as more particularly described hereinafter.
- the primary purpose of the present invention is to provide compositions and methods for in-situ solidification of oil-base drilling muds and for forming oil-base universal fluid filter cakes which can be solidified.
- cement is used in reference to Portland cement or other available hydraulic materials. Most of the exemplification herein is based on using Portland cements.
- the type of oil in the oil-base mud is usually not critical to the cementing process in the present context. If necessary, a satisfactory oil mud cement slurry could be made from pure oil by adding sufficient amounts of cement, water, emulsifiers, fluid loss additives, suspending agents, accelerators, etc.
- Drilling muds are used for the present in-situ conversion process for many reasons.
- the oil-base mud is already present at the well site in the large quantities necessary for cementing the well. All (or most) of the emulsifying, stabilizing, and fluid loss control materials, and a major portion of the mechanical shearing necessary to produce a good emulsion already have been incorporated into the mud to be converted to an oil mud cement slurry. It is much easier, less expensive, and less time consuming to make adjustments to a preexisting invert emulsion mud (oil-base mud) than to build one from scratch.
- drilling mud left after the drilling of a well must be disposed.
- Oil-base muds are even more of an environmental problem than are water-base muds. If a large portion of the leftover drilling mud is used to cement the well, the total disposal expense can be substantially reduced.
- a satisfactory oil mud cement slurry must have a sufficiently high ratio of total solids-to-oil so that the solids particles will be closely spaced, and growing cement hydrate crystals can link to each other and adjacent solids particles to give a strong, unified, cohesive structure without the separation of oil from the solid mass.
- the total solids (cement plus the solids already in the mud)-to-oil volume ratio can vary from about 1.4 to 2.2.
- the present slurry design is a two-step process: first, enough cement, and second, enough water.
- Drilling muds having a low oil-to-water ratio are preferred (but not necessary) according to the following reasoning.
- High water means lower oil content so less cement is required to provide the correct solids-to-oil ratio. This lowered cement content then requires less additional water for hydration. If a stable high-water oil-base mud is used, additional emulsifiers probably will not be required.
- Low-water oil-base muds usually require additional emulsifiers and stabilizers to produce a good oil mud cement. Thus lower added volumes and costs are required for each barrel of the excess high-water drilling mud used. Also, more barrels of the drilling mud are used to produce the required fluid volume of oil mud cement and the ultimate disposal costs are reduced.
- the present invention includes a composition and method for drilling with an oil base universal fluid and for providing a filter cake (formed as a permeable formation is drilled with an oil-base mud) which can be solidified to form a cementitious structure intimately bound to the formation itself.
- the present invention provides a method for cementing a well comprising admixing an oil mud with (a) sufficient hydraulic material and water to form a slurry having a total solids-to-oil volume ratio of about 1.4 to 2.2 and a water-to-hydraulic material weight ratio of about 0.15 to 0.60, and (b) sufficient accelerator or retarder to cause the oil mud cement to harden and set up at a preselected time; and displacing the slurry to a preselected location in the well, and allowing the oil mud cement to harden and set up.
- the present invention also provides a composition for cementing a well comprising an oil mud containing sufficient hydraulic material and water to form a slurry having (a) a total solids-to-oil volume ratio of about 1.4 to 2.2 and a water-to-hydraulic material weight ratio of about 0.15 to 0.60, and (b) sufficient accelerator or retarder to cause the oil mud-cement to harden and set up at a preselected time.
- high water oil-base muds with an alkali metal halide (preferably sodium chloride) internal phase, are particularly suitable for forming oil mud cements.
- alkali metal halide preferably sodium chloride
- calcium chloride brine muds usually are preferred in field drilling operations, it has been found that it is generally not satisfactory to use calcium chloride in the formation of an oil mud cement.
- conventional invert oil muds e.g., having an oil-to-water volume ratio of 95:5 to 70:30, also can be used for in-situ mud conversion, although additional emulsifiers and stabilizers may be required.
- high water it is intended to mean an oil-to-water volume ratio of approximately 30:70 to 70:30, with a ratio of about 50:50 being optimal.
- the high water oil-base muds must be formulated to have high emulsion stability with large amounts of water under high temperature drilling conditions. Such muds must tolerate the high water content and maintain reasonable rheological properties comparable to those of regular invert oil muds.
- a highly contamination-resistant mud is desired because a large quantity of cement and extra water are added to the mud system in order to convert the mud into a high-compression strength mud concrete. The addition of any necessary emulsifiers, stabilizers or wetting agents adds to the cost of the system.
- One barrel of a representative 13.5 lb/gal mud suitable for use in the invention has a composition as follows: diesel oil, 0.42 barrels; lime, 2.4 pounds; "CARBO-TEC L” (primary emulsifier, tall oil fatty acids, by Milpark Drilling Fluids), 1 gallon (8.1 pounds); water, 0.42 barrels; sodium chloride, 49 pounds; “CARBO-MUL” (secondary, emulsifier, tall oil polyamide, by Milpark), 1 gallon (7.7 pounds); “SURFCOTE” (wetting agent, amine dodecyl benzene sulfonate, by Milpark), 2.0 pounds; barite, 312 pounds.
- While the preceding mud formulation is with diesel oil, it is to be understood that other oils or hydrocarbons may be employed.
- diesel oil-based muds The use of diesel oil-based muds is restricted in many parts of the world because of environmental concerns.
- Non-toxic, mineral or "clean" oil muds offer the benefits of an oil-base mud while maintaining a toxicity near that of water-base muds.
- non-toxic mineral oils such as Exxon's "ESCAID 110" (1.6 csf @ 40° C.), Conoco's “LVT 200” , Vista's “ODC”, and Shell's “SOL DMA” are available. These oils are considerably thinner than diesel oil (3.7 csf @ 40° C.), but can be used satisfactorily for making low toxicity oil-base muds.
- a sodium chloride salt with the oil mud of the present invention.
- Calcium chloride brine muds are very difficult to use, giving many thickening, emulsion-breaking, and fluid separation problems even while mixing. The calcium chloride slurries become very thick during mixing and never attain a satisfactory set strength for use herein. Thus, although calcium chloride brine muds usually are preferred in field drilling operations, they are not desirable for making the oil mud cements.
- Other less preferred salts which may be suitable for use with the invention include potassium chloride, zinc chloride, sodium nitrate, and ammonium sulfate.
- the present invention utilizes an oil base mud to which is added cement and extra water if desired for additional cement hydration.
- the dry cement particles are coated with the oil phase and the extra water is dispersed as the internal emulsified phase (adding to the emulsified water already present in the mud).
- the water becomes available to the cement for hydration by an osmosis-like process across a semi-permeable membrane of oil and surfactants between the water droplets and the cement particles.
- An osmotic pressure causes water molecules to migrate across the semi-permeable membrane from the high vapor pressure (wet) water droplets to the low vapor pressure (dry) cement particles.
- Water molecules arriving at the cement combine with the "water thirsty" cement particles to form calcium silicate hydrate crystals.
- the calcium silicate hydrate crystals grow and extend through the surrounding oil phase, link together, and form a competent set cement structure. As long as the vapor pressure of the cement particles remains low, the osmosis of water occurring in the cement hydration reactions will continue.
- the majority of water present in the mud is consumed by the cement hydration reactions, and the emulsion droplets are used up as the oil mud cement sets.
- the water-internal emulsion does not break during setting.
- the oil remains evenly dispersed in the set mass, and no water or oil separates from the set oil mud cement. Any separated fluids would produce undesirable channels in the set oil mud cement.
- the hydration reactions are accelerated by increased temperature, which increases the chemical potential (vapor pressure driving force), and by high mechanical shear during preparation and well operations. This mechanical energy helps to generate a large number of small water droplets which lie closer to the cement particles.
- the cement accelerators increase the rate of early strength development by decreasing the dormant or induction period in the hydration of portland cement.
- a large amount of cement is added to the drilling mud to make a slurry that can attain the desired set strength. Water is necessary for the cement hydration which produces the set strength. If enough water is not already present in the stable oil-base mud, it must be added. A water-to-cement weight ratio of about 0.15 to 0.60 is preferred and optimally about 0.30 to 0.35. If a high-water oil-base mud is used, the mud has already been conditioned to withstand a high water content and it will probably remain stable when the cement and extra water (if necessary) is added without requiring treatment with expensive emulsifiers, stabilizers or wetting agents.
- the oil-base mud with an oil-to-water volume ratio of 30:70 to 70:30 has been specified with a practical optimum of about 50:50.
- Water in excess of the amount needed to hydrate the cement will increase the viscosity (as water is the internal phase), reduce the slurry density, and remain unreacted in the set oil mud-cement mass, thus reducing compressive strength and increasing porosity and permeability.
- the water required for complete cement hydration is about 25% of the weight of cement.
- water-to-cement values of 35% to 45% by weight are used to provide sufficient fluidity and density control.
- a water-to-cement value of 35% by weight usually has been used to be sure that complete cement hydration takes place.
- Another significant variable of the present invention is the amount of solids in the oil mud-cement slurry.
- a solids-to-oil ratio by volume of 1.4 to 2.2, and optimally 1.80 is preferred. Any oil in excess of the amount needed to coat all of the added cement particles and to provide sufficient fluidity for mixing and pumping will remain as an inert diluent in the set oil mud cement mass, reducing the compressive strength and giving increased porosity and permeability.
- a constant volume ratio of the total solids (mud solids plus cement)-to-oil By using a constant volume ratio of the total solids (mud solids plus cement)-to-oil, a nearly comparable fluidity is attainable using any oil mud.
- the amount of oil is fixed in a given base mud and no extra oil is required.
- a solids-to-oil volume ratio of 1.8 appears to be optimum. From this solids-to-oil volume ratio value, the amount of cement needed is determined. Then, based on a chosen water-to-cement ratio, the amount of supplemental water is calculated.
- Portland cement is economical, is widely available as a finely ground powder, and usually is very suitable for use.
- Other hydraulic materials such as fly ash, natural pozzolan, trass, tuff, and blast furnace slag may be usable for these purposes. None of these latter agents, however, performs as well as Portland cement which is preferred.
- Class C or A cement gives higher strength than does Class G or H, and accordingly, Class C or A is generally preferred.
- oil mud-cements preferably are prepared by adding a Portland cement to an oil-base mud.
- An emulsified internal water phase is necessary to allow hydration of the cement.
- Supplemental water may be emulsified in the system to provide more hydration.
- the cement disperses in the oil phase and remains out of contact with the water under normal conditions of mixing and storage. With time and/or higher temperatures, the water becomes available in the cement and the cement hydration reaction proceeds, giving a solid set mass.
- the slurry viscosity, the setting time, and the set strength of the slurries of the present invention can be adjusted using appropriate oil-wetting agents, emulsifiers, and accelerators, as well as controlling temperature.
- the mechanism by which the setting occurs is not fully understood, but with increased temperature, the rate of setting is greatly increased.
- the mud should be able to accept addition of the cement and extra water while maintaining stable properties so that the resulting slurry can be mixed and pumped into a wellbore.
- the water molecules With time at elevated temperatures, the water molecules apparently migrate through the oil phase to the cement particles by an osmosis-like process. The cement then slowly hydrates, and the calcium silica hydrate crystals grow through the oil phase to link and form a solid structure.
- Another significant variable of the invention is the additives employed in the system. These various additions, used in effective amounts, can provide set acceleration, retardation, or viscosity control as well as additional emulsification or oil wetting properties if needed for the incorporation of the cement or extra water.
- Set accelerators are desirable to provide sufficient set strength within a reasonable time.
- "POZZUTEC-20” (a proprietary commercial low temperature accelerator of mixed organic and inorganic salts made by Master Builders for the construction industry) is an effective accelerator.
- FAM an acronym for a mixture of 45% by volume formic acid, 45% by volume acetic acid, and 10% by volume methanol
- MSF manganesium silicofluoride
- ZSF zinc silicofluoride
- SURFCOTE Milpark oil wetting agent believed to contain dodecyl benzeneaminesulfonate
- SurfCote is also a strong set retarder.
- CARBO-TEK L primarily a modified tall oil fatty acid
- CARBO-MUL secondary emulsifier
- CARBO-DRILL composition undisclosed
- emulsifying and stabilizing agents are used to give the oil mud-cement stability for whatever conditions are necessary. It is preferred, however, not to overtreat the oil mud-cement system since such agents are expensive and frequently are strong set retarders. Any over-retardation then requires additional accelerators to give a set within the desired time.
- three similar oil-base muds designated Na-1, Na-2, and Na-3) were mixed in the laboratory. Na-1 had moderate amounts of the emulsifiers and stabilizers; Na-2, excessive amounts; Na-3, minimal amounts.
- a base oil mud-cement slurry was made by adding cement extra water, and any additives to the oil muds using normal lab mixers and Hamilton-Beach high-speed mixers. Equal portions (20 ml) of this base slurry were then measured into small glass vials (32 ml) for test series.
- the samples were sealed in the vials and heat aged statically for hardening. The large majority of the samples were aged at either 150° F. or 180° F.
- the setting of the oil mud-cement (OMC) samples were monitored with time using a spatula "hardness" test in the vials. The hardness scale ranged from 0 to 10, with 0 being completely fluid and 10 being "rock hard.” A hardness of 9 corresponds to a compressive strength of approximately 150 psi. Samples with hardness greater than 9 were retested using a Brinell tester to estimate equivalent compressive strengths measured in psi.
- Table A shows the effects of changing the solids-to-oil ratio studied in the absence of accelerators using a base mud system, Na-2.
- the amount of Class A cement needed to give the same solids-to-oil ratio varies with mud composition. Higher solids-to-oil ratios seem to produce slightly higher compressive strength.
- the samples prepared using the Na-2 mud were strongly retarded and did not set.
- the Na-2 mud contained both SurfCote, a powerful oil wetting agent, and CarboDrill, an experimental emulsifier of undisclosed chemical composition.
- the two slurries (OMC 358 and 359) shown in Table A were used as base slurries to study the effectiveness of several accelerators.
- the setting of base slurries OMC 358 and 359 using the highly retarded Na-2 mud was accomplished only by adding 7.5 lb/bbl Pozzutec 20.
- API Class A cement at 600 lb/bbl levels was added to specially formulated high-water oil emulsion muds, Na-2, along with several accelerators and setting agents. Accelerators are added to the OMC slurries to speed the reactions and to attain a higher set strength within a reasonable time. They were Pozzutec 20 (PT-20), magnesium silicofluoride (MSF) and zinc silicofluoride (ZSF). Pozzutec 20 is a low temperature accelerator from Master Builders used in the construction industry.
- Table B shows that (1) a temperature increase from 150° F. to 180° F. increases the compressive strength, (2) a PT-20 (Pozzutec 20) concentration of 7.5 lb/bbl seems to be about optimum, and (3) MSF and ZSF appear to be about equivalent, but Pozzutec 20, at a concentration of 7.5 lb/gal appears to be superior to either of them.
- Table C shows that OMC 393 had a compressive strength of 1,300 psi. This was achieved by adding 7.5 lb/bbl Pozzutec 20 and 1.75 lb/bbl cyclohexanol in a Na-2 base mix which contains 600 lb/bbl Class A cement and 107 lb/bbl additional water. In this case, the cyclohexane doubled the strength of a comparable slurry, but in two other cases it slightly decreased the strength, and in the fourth case it completely prevented set. Although the role of cyclohexanol was not clear, it may have acted as a mutual solvent such that the cement hydration reactions were improved.
- Table E lists the test results of Na-4 and Na-5 (conventional low water oil mud) muds.
- the Na-5 mud is a 14.3 lb/gal Milpark CarboDrill with an oil-to-water ratio of 87:13.
- the Na-5 mud is not a "high water” mud.
- the base mix 449 did not set.
- OMC 451 made from the Na-5 mud set hard and both contained 7.5 lb/bbl Pozzutec 20. The effect of FAM on set acceleration is not as good as that of Pozzutec 20.
- the base slurry OMC 449 contains 921 lb/bbl Class A cement and 335 lb/bbl water in order to maintain a solids-to-oil ratio of 1.8 and a water-to-cement ratio of 40 percent. This will result in a volume increase of 180 percent based on the original mud volume. It is quite clear that a considerable amount of cement is needed to absorb the large amount of oil present in the Na-5 (conventional) oil mud. Considerable amounts of extra water are also needed to provide sufficient water for the cement hydration.
- a 12-barrel batch of a 13.5 ppg Milpark's CarboDrill-HW mud (designated as Na-7 mud) was prepared. This is a "high water” content oil mud with an oil-to-water ratio of 50:50.
- the formulation of this mud is as follows:
- a 12-barrel (504 gallons) batch of the above-listed mud was prepared and stabilized by stirring and pumping with high shear within the mixing unit. Portions of this mud were used for the two tests.
- the test slurries were batch-mixed, using this stabilized mud, with a high shear mixer (RCM cement mixing unit) just prior to their displacement into and circulation through the test model using a triplex pump.
- RCM cement mixing unit just prior to their displacement into and circulation through the test model using a triplex pump.
- a slurry sample collected during the OMC-2 test was run on an ultrasonic cement analyzer (UCA). Although the ultrasonic cement analyzer indicated a strength of 534 psi, its core recovered after the ultrasonic cement analyzer test was crushed, giving a compressive strength of 1,108 psi.
- UCA ultrasonic cement analyzer
- Compressive strength data were obtained as checks of the effects of time and temperature on the oil mud-cement slurry and the heat aging samples.
- a one lab-barrel (350 ml) sample of the large test batch of the base mud was made into an oil mud-cement using the same composition as used in the displacement tests. Small vial samples of this oil mud-cement were then heat aged at 180° F. 200° F., and 210° F., leaving the main portion at room temperature. These three samples showed increased compressive strength with increased aging temperature (1,104, 1,304, and 1,385 psi, respectively, all at 2.8 days curing time).
- this time related non-setting phenomenon has been reversed by a strong mechanical shearing.
- the setting by the addition of more accelerator combined with the strong mechanical shearing has been required to initiate the test.
- Each of the two test models with the solidified oil mud-cements supporting the 5-inch casing in the permeable 61/2-inch simulated borehole was cut horizontally (perpendicular to its 15-foot axis) 80 inches from the top.
- the lower sections (from the 80- to the 180-inch levels) were used for the hydraulic bond tests.
- the entire length of the model was used for the shear bond tests.
- Epoxy cement was then used to bond small pipe nipples, for use as pressure taps, all the way into the holes, sealing all the layers exposed by the drilling. After the epoxy had hardened a hole was drilled down the axis of each of the first set of nipples, through the remaining part of the permeable layer, and just into the filter cake layer, thus exposing the formation-filter cake junction. A hole was also drilled down the axis of each of the second set of nipples, through the remaining part of the oil mud-cement layer, and just into the inner casing surface, thus exposing the oil mud-cement casing junction.
- the "hydraulic bond" at each of the formation-cake junctions and the oil mud-cement casing junctions was successively measured by injecting water through the pressure tap at a rate of four ml per minute until a pressure breakdown was noted. The maximum pressure at each tap was recorded as the hydraulic bond.
- the entire model was cut into 10-inch lengths (except for the 60-80-inch level section which was left 20 inches long).
- the shear bond tests were then run on each section on a hydraulic press by pressing first on the 5-inch casing to measure the oil mud-cement to pipe bond and then on the set oil mud-cement area to measure the oil mud-cement to formation bond.
- the LC OMC (containing one-half the amount of the cement needed for OMC-2 and 8.4 lb/bbl Pozzutec 20) was tested as an oil-base universal fluid. This fluid was circulated in the model and left pressurized static overnight to deposit a settable filter cake in the test model. This LC OMC fluid was displaced by circulating the full OMC-2 slurry in the model at the end of the static filtration period. The entire system was then left static and pressurized to cure at elevate temperatures.
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Abstract
A water-in-oil emulsion drilling fluid can be converted into an oil mud-cement slurry for use in oil well cementing procedures. Also, a universal fluid can be prepared using the water-in-oil emulsion drilling fluid by treating with an hydraulic material so that it will lay down a filter cake during drilling which can be triggered to set into a hard cement and bond to the formation after the above oil mud-cement slurry has been placed in the borehole at the conclusion of drilling.
Description
This is a continuation of application Ser. No. 691,904, now abandoned, filed Apr. 26, 1991.
1. Field of the Invention
The present invention pertains to improvements in compositions and methods for zonal isolation for vertical, deviated, and horizontal oil and gas wells. The method involves the utilization of oil-base universal fluid for providing settable filter cake while drilling and the subsequent in-situ solidification of the drilling mud or both the drilling mud and universal fluid filter cake to compressive strengths well in excess of that required for casing support, zonal isolation, and borehole stability.
2. Description of Prior Art
The general procedure of drilling an oil or gas well includes drilling a borehole using a drilling fluid (also termed drilling mud). Subsequent to drilling the borehole casing is run into the well and a cement slurry is then placed in the annulus between the outside of the casing and the borehole wall. In order to obtain a good cementing job, it is necessary for the cement slurry to displace substantially all of the drilling mud from the annulus. A reduced displacement efficiency arises from the geometry of the system and also from the fact that drilling fluids and cements are usually incompatible.
Nondisplaced mud (mud still left in the borehole after cementing) and mud filter cake are major causes of unsatisfactory cement performance. Since the nondisplaced mud and mud filter cake do not set or bond to the casing, the borehole wall or the set cement itself, the mud and filter cake do not support the casing properly and later can allow annular gas or fluid migration.
Wells frequently are drilled with oil-base muds which contain water as the internal emulsified phase. These oil-base muds are used, for example, to lower drilling torque and drag, reduce damage to productive formations, increase wellbore stability or reduce differential pressure pipe sticking, etc. The presence of oil mud in the wellbore can even further reduce the displacement efficiency while cementing with a conventional water-base cement slurry.
The drilling industry has sought to overcome the above problems by using a variety of techniques to displace the drilling fluid with cement, e.g., turbulent flow, casing movement (reciprocation/rotation), casing equipment (centralizers, flow diverters, mud cake scratchers), and special spacers and wash fluids, but these have had limited success. Even greater cementing difficulties are encountered when the boreholes deviate greatly from vertical. Major problems arise in connection with casing placement, drilled solids settling, mud displacement, casing centralization, fluid separation (free water), and mechanical friction. When a good cementing job is not obtained, it may be necessary to perforate the casing and squeeze cement under high pressure through the perforations into the annulus and try to fill the zones that were not properly cemented initially. Frequently, this squeeze cementing is not successful, and such failures may eventually lead to abandoning the hole.
One of the major objectives of a primary cementing is to obtain good zonal isolation in the annulus of the well. Effective zonal isolation is achieved by sealing the cement and borehole wall. The interface of the cement and borehole wall is usually an interface between the cement and drilling fluid filter cake which is the source of many cementing problems. Good zonal isolation can be achieved if the filter cake hardens, permanently bonds to the formation face and the cement, and provides hydraulic sealing.
Accordingly, the present invention is directed to overcoming the above-noted problems in the art and to providing a solution as more particularly described hereinafter.
The primary purpose of the present invention is to provide compositions and methods for in-situ solidification of oil-base drilling muds and for forming oil-base universal fluid filter cakes which can be solidified.
Hereinafter, the term "cement" is used in reference to Portland cement or other available hydraulic materials. Most of the exemplification herein is based on using Portland cements. The type of oil in the oil-base mud is usually not critical to the cementing process in the present context. If necessary, a satisfactory oil mud cement slurry could be made from pure oil by adding sufficient amounts of cement, water, emulsifiers, fluid loss additives, suspending agents, accelerators, etc.
Drilling muds are used for the present in-situ conversion process for many reasons. The oil-base mud is already present at the well site in the large quantities necessary for cementing the well. All (or most) of the emulsifying, stabilizing, and fluid loss control materials, and a major portion of the mechanical shearing necessary to produce a good emulsion already have been incorporated into the mud to be converted to an oil mud cement slurry. It is much easier, less expensive, and less time consuming to make adjustments to a preexisting invert emulsion mud (oil-base mud) than to build one from scratch.
In addition, drilling mud left after the drilling of a well must be disposed. Oil-base muds are even more of an environmental problem than are water-base muds. If a large portion of the leftover drilling mud is used to cement the well, the total disposal expense can be substantially reduced.
A satisfactory oil mud cement slurry must have a sufficiently high ratio of total solids-to-oil so that the solids particles will be closely spaced, and growing cement hydrate crystals can link to each other and adjacent solids particles to give a strong, unified, cohesive structure without the separation of oil from the solid mass. The total solids (cement plus the solids already in the mud)-to-oil volume ratio can vary from about 1.4 to 2.2.
Sufficient water must be present in the slurry to allow for hydration of the dry cement particles. Extra water is normally added even to the slurries prepared from high water content oil-base muds. This is to provide hydration water for the total cement added to satisfy the desired solids-to-oil ratio. Thus, the present slurry design is a two-step process: first, enough cement, and second, enough water.
Drilling muds having a low oil-to-water ratio (high water) are preferred (but not necessary) according to the following reasoning. High water means lower oil content so less cement is required to provide the correct solids-to-oil ratio. This lowered cement content then requires less additional water for hydration. If a stable high-water oil-base mud is used, additional emulsifiers probably will not be required. Low-water oil-base muds usually require additional emulsifiers and stabilizers to produce a good oil mud cement. Thus lower added volumes and costs are required for each barrel of the excess high-water drilling mud used. Also, more barrels of the drilling mud are used to produce the required fluid volume of oil mud cement and the ultimate disposal costs are reduced.
In conjunction with the method and composition for the solidification of an oil-base drilling mud, the present invention includes a composition and method for drilling with an oil base universal fluid and for providing a filter cake (formed as a permeable formation is drilled with an oil-base mud) which can be solidified to form a cementitious structure intimately bound to the formation itself.
Accordingly, the present invention provides a method for cementing a well comprising admixing an oil mud with (a) sufficient hydraulic material and water to form a slurry having a total solids-to-oil volume ratio of about 1.4 to 2.2 and a water-to-hydraulic material weight ratio of about 0.15 to 0.60, and (b) sufficient accelerator or retarder to cause the oil mud cement to harden and set up at a preselected time; and displacing the slurry to a preselected location in the well, and allowing the oil mud cement to harden and set up.
The present invention also provides a composition for cementing a well comprising an oil mud containing sufficient hydraulic material and water to form a slurry having (a) a total solids-to-oil volume ratio of about 1.4 to 2.2 and a water-to-hydraulic material weight ratio of about 0.15 to 0.60, and (b) sufficient accelerator or retarder to cause the oil mud-cement to harden and set up at a preselected time.
Other purposes, distinctions over the art, advantages and features of the invention will be apparent to one skilled in the art upon review of the following.
The following preferred embodiments of the invention, together with the following examples, explain the principles of the invention.
In accordance with the present invention, it has been discovered that high water oil-base muds, with an alkali metal halide (preferably sodium chloride) internal phase, are particularly suitable for forming oil mud cements. Although calcium chloride brine muds usually are preferred in field drilling operations, it has been found that it is generally not satisfactory to use calcium chloride in the formation of an oil mud cement. Also, although not preferred, conventional invert oil muds, e.g., having an oil-to-water volume ratio of 95:5 to 70:30, also can be used for in-situ mud conversion, although additional emulsifiers and stabilizers may be required. By the term "high water" it is intended to mean an oil-to-water volume ratio of approximately 30:70 to 70:30, with a ratio of about 50:50 being optimal. The high water oil-base muds must be formulated to have high emulsion stability with large amounts of water under high temperature drilling conditions. Such muds must tolerate the high water content and maintain reasonable rheological properties comparable to those of regular invert oil muds. A highly contamination-resistant mud is desired because a large quantity of cement and extra water are added to the mud system in order to convert the mud into a high-compression strength mud concrete. The addition of any necessary emulsifiers, stabilizers or wetting agents adds to the cost of the system.
One barrel of a representative 13.5 lb/gal mud suitable for use in the invention has a composition as follows: diesel oil, 0.42 barrels; lime, 2.4 pounds; "CARBO-TEC L" (primary emulsifier, tall oil fatty acids, by Milpark Drilling Fluids), 1 gallon (8.1 pounds); water, 0.42 barrels; sodium chloride, 49 pounds; "CARBO-MUL" (secondary, emulsifier, tall oil polyamide, by Milpark), 1 gallon (7.7 pounds); "SURFCOTE" (wetting agent, amine dodecyl benzene sulfonate, by Milpark), 2.0 pounds; barite, 312 pounds. While the preceding mud formulation is with diesel oil, it is to be understood that other oils or hydrocarbons may be employed. The use of diesel oil-based muds is restricted in many parts of the world because of environmental concerns. Non-toxic, mineral or "clean" oil muds offer the benefits of an oil-base mud while maintaining a toxicity near that of water-base muds. Currently, non-toxic mineral oils such as Exxon's "ESCAID 110" (1.6 csf @ 40° C.), Conoco's "LVT 200" , Vista's "ODC", and Shell's "SOL DMA" are available. These oils are considerably thinner than diesel oil (3.7 csf @ 40° C.), but can be used satisfactorily for making low toxicity oil-base muds.
As above mentioned, it is highly preferred to use a sodium chloride salt with the oil mud of the present invention. Calcium chloride brine muds are very difficult to use, giving many thickening, emulsion-breaking, and fluid separation problems even while mixing. The calcium chloride slurries become very thick during mixing and never attain a satisfactory set strength for use herein. Thus, although calcium chloride brine muds usually are preferred in field drilling operations, they are not desirable for making the oil mud cements. Other less preferred salts which may be suitable for use with the invention include potassium chloride, zinc chloride, sodium nitrate, and ammonium sulfate.
As also above mentioned, the present invention utilizes an oil base mud to which is added cement and extra water if desired for additional cement hydration. The dry cement particles are coated with the oil phase and the extra water is dispersed as the internal emulsified phase (adding to the emulsified water already present in the mud).
The water becomes available to the cement for hydration by an osmosis-like process across a semi-permeable membrane of oil and surfactants between the water droplets and the cement particles. An osmotic pressure causes water molecules to migrate across the semi-permeable membrane from the high vapor pressure (wet) water droplets to the low vapor pressure (dry) cement particles. Water molecules arriving at the cement combine with the "water thirsty" cement particles to form calcium silicate hydrate crystals. The calcium silicate hydrate crystals grow and extend through the surrounding oil phase, link together, and form a competent set cement structure. As long as the vapor pressure of the cement particles remains low, the osmosis of water occurring in the cement hydration reactions will continue. The majority of water present in the mud is consumed by the cement hydration reactions, and the emulsion droplets are used up as the oil mud cement sets. The water-internal emulsion does not break during setting. The oil remains evenly dispersed in the set mass, and no water or oil separates from the set oil mud cement. Any separated fluids would produce undesirable channels in the set oil mud cement.
The hydration reactions are accelerated by increased temperature, which increases the chemical potential (vapor pressure driving force), and by high mechanical shear during preparation and well operations. This mechanical energy helps to generate a large number of small water droplets which lie closer to the cement particles. The cement accelerators increase the rate of early strength development by decreasing the dormant or induction period in the hydration of portland cement.
While various waters maybe used with the present invention, such as fresh water, brackish water brine, seawater or other water-containing fluids, for ease of control it is preferred that fresh water added to allow full hydration of the cement be used. Waters other than fresh might have various materials (e.g., salts, lignins or tannins) present which could affect the cement hydration rates.
Not only is the type of water employed significant, but it is also considered important that the correct amount of water be utilized. A large amount of cement is added to the drilling mud to make a slurry that can attain the desired set strength. Water is necessary for the cement hydration which produces the set strength. If enough water is not already present in the stable oil-base mud, it must be added. A water-to-cement weight ratio of about 0.15 to 0.60 is preferred and optimally about 0.30 to 0.35. If a high-water oil-base mud is used, the mud has already been conditioned to withstand a high water content and it will probably remain stable when the cement and extra water (if necessary) is added without requiring treatment with expensive emulsifiers, stabilizers or wetting agents. Thus the oil-base mud with an oil-to-water volume ratio of 30:70 to 70:30 has been specified with a practical optimum of about 50:50. Water in excess of the amount needed to hydrate the cement will increase the viscosity (as water is the internal phase), reduce the slurry density, and remain unreacted in the set oil mud-cement mass, thus reducing compressive strength and increasing porosity and permeability. Theoretically, the water required for complete cement hydration is about 25% of the weight of cement. In normal practice oil well cementing, water-to-cement values of 35% to 45% by weight are used to provide sufficient fluidity and density control. Hereinafter, a water-to-cement value of 35% by weight usually has been used to be sure that complete cement hydration takes place.
Another significant variable of the present invention is the amount of solids in the oil mud-cement slurry. A solids-to-oil ratio by volume of 1.4 to 2.2, and optimally 1.80 is preferred. Any oil in excess of the amount needed to coat all of the added cement particles and to provide sufficient fluidity for mixing and pumping will remain as an inert diluent in the set oil mud cement mass, reducing the compressive strength and giving increased porosity and permeability. By using a constant volume ratio of the total solids (mud solids plus cement)-to-oil, a nearly comparable fluidity is attainable using any oil mud. The amount of oil is fixed in a given base mud and no extra oil is required. A solids-to-oil volume ratio of 1.8 appears to be optimum. From this solids-to-oil volume ratio value, the amount of cement needed is determined. Then, based on a chosen water-to-cement ratio, the amount of supplemental water is calculated.
Another important variable in the present invention is the cement material which is employed. In accordance with the present invention it has been found that Portland cement is economical, is widely available as a finely ground powder, and usually is very suitable for use. Other hydraulic materials such as fly ash, natural pozzolan, trass, tuff, and blast furnace slag may be usable for these purposes. None of these latter agents, however, performs as well as Portland cement which is preferred. Among the Portland cements, Class C or A cement gives higher strength than does Class G or H, and accordingly, Class C or A is generally preferred.
It has been found that oil mud-cements set harder and more rapidly at 180° F. than at 150° F. Thus, to the extent that temperature is controllable, it is possible to control the setting rate of the oil mud-cement. Normally, the control of temperature in a well is not within the scope of the operator, at least to any significant degree.
Essentially, oil mud-cements preferably are prepared by adding a Portland cement to an oil-base mud. An emulsified internal water phase is necessary to allow hydration of the cement. Supplemental water may be emulsified in the system to provide more hydration. The cement disperses in the oil phase and remains out of contact with the water under normal conditions of mixing and storage. With time and/or higher temperatures, the water becomes available in the cement and the cement hydration reaction proceeds, giving a solid set mass.
The slurry viscosity, the setting time, and the set strength of the slurries of the present invention can be adjusted using appropriate oil-wetting agents, emulsifiers, and accelerators, as well as controlling temperature. The mechanism by which the setting occurs is not fully understood, but with increased temperature, the rate of setting is greatly increased. Initially, the mud should be able to accept addition of the cement and extra water while maintaining stable properties so that the resulting slurry can be mixed and pumped into a wellbore. With time at elevated temperatures, the water molecules apparently migrate through the oil phase to the cement particles by an osmosis-like process. The cement then slowly hydrates, and the calcium silica hydrate crystals grow through the oil phase to link and form a solid structure. The oil and any unreacted water remain evenly dispersed in the set cement. Too little water will not produce sufficient hydration to give strength, while too much water unnecessarily increases the porosity and permeability and reduces the strength. Any oil present in excess of that required to coat all of the solid materials and to provide sufficient fluidity remains in the solidified mass, increasing the porosity and permeability and reducing the ultimate strength. Properly prepared oil mud-cements have very low air permeabilities.
Another significant variable of the invention is the additives employed in the system. These various additions, used in effective amounts, can provide set acceleration, retardation, or viscosity control as well as additional emulsification or oil wetting properties if needed for the incorporation of the cement or extra water.
Set accelerators are desirable to provide sufficient set strength within a reasonable time. "POZZUTEC-20" (a proprietary commercial low temperature accelerator of mixed organic and inorganic salts made by Master Builders for the construction industry) is an effective accelerator. By itself, FAM (an acronym for a mixture of 45% by volume formic acid, 45% by volume acetic acid, and 10% by volume methanol) is not as effective as Pozzutec-20 but it seems to work very well in combination with the Pozzutec-20. Formic acid and acetic acid separately give some acceleration but appear to work more effectively in combination and with methanol. MSF (magnesium silicofluoride) and ZSF (zinc silicofluoride) appear to be about equivalent but not as effective as either FAM or Pozzutec-20. "SURFCOTE" (a Milpark oil wetting agent believed to contain dodecyl benzeneaminesulfonate) is the only agent found to have a thinning effect on the oil mud cement other than the thinning effect afforded by mere oil dilution. However, SurfCote is also a strong set retarder.
To help stabilize the high water content of the oil mud cements, inclusion of additional emulsifiers may be required. Milpark's primary emulsifier "CARBO-TEK L" (primarily a modified tall oil fatty acid), their secondary emulsifier "CARBO-MUL" (known as tall oil polyamide), and their "CARBO-DRILL" (composition undisclosed), an experimental emulsifier for high water content oil muds, have been useful for this purpose.
The above-mentioned emulsifying and stabilizing agents are used to give the oil mud-cement stability for whatever conditions are necessary. It is preferred, however, not to overtreat the oil mud-cement system since such agents are expensive and frequently are strong set retarders. Any over-retardation then requires additional accelerators to give a set within the desired time. For example, three similar oil-base muds (designated Na-1, Na-2, and Na-3) were mixed in the laboratory. Na-1 had moderate amounts of the emulsifiers and stabilizers; Na-2, excessive amounts; Na-3, minimal amounts. Oil mud-cement slurries of each, made by adding the same calculated ratios of cement-to-solids and water-to-cement, were then placed in a 180° F. oven to cure. Oil mud-cement prepared from Na-1 became hard in five days; oil mud-cement prepared from Na-2 did not become hard even by 36 days; and oil mud-cement prepared from Na-3 became hard by one day. The addition of 7.5 lb/bbl of Pozzutec-20 made both oil mud-cements made from Na-1 and Na-2 also become hard in one day.
Screening tests were conducted in small glass vials. A base oil mud-cement slurry was made by adding cement extra water, and any additives to the oil muds using normal lab mixers and Hamilton-Beach high-speed mixers. Equal portions (20 ml) of this base slurry were then measured into small glass vials (32 ml) for test series.
The samples were sealed in the vials and heat aged statically for hardening. The large majority of the samples were aged at either 150° F. or 180° F. The setting of the oil mud-cement (OMC) samples were monitored with time using a spatula "hardness" test in the vials. The hardness scale ranged from 0 to 10, with 0 being completely fluid and 10 being "rock hard." A hardness of 9 corresponds to a compressive strength of approximately 150 psi. Samples with hardness greater than 9 were retested using a Brinell tester to estimate equivalent compressive strengths measured in psi. All laboratory testing used Milpark's 13.5 lb/gal CarboDrill-HW oil mud (oil-to-water ratio of 50:50) with a 25 percent sodium chloride brine as the internal phase. The water added to allow full hydration of the cement was fresh water rather than brine.
Table A shows the effects of changing the solids-to-oil ratio studied in the absence of accelerators using a base mud system, Na-2. The amount of Class A cement needed to give the same solids-to-oil ratio varies with mud composition. Higher solids-to-oil ratios seem to produce slightly higher compressive strength.
TABLE A ______________________________________ Solidification of Various 14 lb/gal CarboDrill-HW Muds Without Adding Any Accelerator: Effect of Maintaining a Constant Water-to-Cement Ratio and Varying Total Solids-to-Oil Ratio (SOR) on Compressive Strength of Samples Cured Static at 180° F. Com- pressive Class A Water Hardness Strength Mud Cement (lb/ w/Time (psi) Slurry Type SOR (lb/bbl) bbl) (in days) (GHN) ______________________________________ OMC 358 Na-2 1.85 617.5 129.5 3.5(24), ns 3.8(36) OMC 359 Na-2 2.0 688.0 157.5 3.7(9), ns 3.7(28), 4.4(36) ______________________________________ Notes: SOR, cement and mud solidsto-oil ratio. 40% bwoc (by weight of cement) water (initial and added) used in all cases. *ns = not set
The samples prepared using the Na-2 mud were strongly retarded and did not set. The Na-2 mud contained both SurfCote, a powerful oil wetting agent, and CarboDrill, an experimental emulsifier of undisclosed chemical composition.
The two slurries (OMC 358 and 359) shown in Table A were used as base slurries to study the effectiveness of several accelerators. The setting of base slurries OMC 358 and 359 using the highly retarded Na-2 mud was accomplished only by adding 7.5 lb/bbl Pozzutec 20.
A series of tests screening candidate accelerators was conducted at 150° F. and 180° F. The hardness test results are listed in Table B. API Class A cement at 600 lb/bbl levels was added to specially formulated high-water oil emulsion muds, Na-2, along with several accelerators and setting agents. Accelerators are added to the OMC slurries to speed the reactions and to attain a higher set strength within a reasonable time. They were Pozzutec 20 (PT-20), magnesium silicofluoride (MSF) and zinc silicofluoride (ZSF). Pozzutec 20 is a low temperature accelerator from Master Builders used in the construction industry.
Table B shows that (1) a temperature increase from 150° F. to 180° F. increases the compressive strength, (2) a PT-20 (Pozzutec 20) concentration of 7.5 lb/bbl seems to be about optimum, and (3) MSF and ZSF appear to be about equivalent, but Pozzutec 20, at a concentration of 7.5 lb/gal appears to be superior to either of them.
TABLE B ______________________________________ Effect of Temperature and Accelerator on Compressive Strength of Set 14 lb/gal CarboDrill Na-2 Mud Hardness/ Hardness/ Compressive Compressive Strength Strength Accelerator (BHN) (BHN) Slurry (lb/bbl) Aged at 150° F. Aged at 180° F. ______________________________________ Base -- 3.51-- -- OMC 1 MSF, 6 9.5/-- 10/570 OMC 2 MSF, 9 9.7/250 9.8/410 OMC 2a ZSF, 9 9.9/440 10/280 OMC 3 ZSF, 9 9.7/410 9.9/850 OMC 4 PT-20, 5.5 9.9/480 10/840 OMC 5 PT-20, 7.5 10/520 10/890 OMC 6 PT-20, 10 10/560 9.8/710 OMC 7 PT-20, 15 10/590 9.9/710 ______________________________________ Notes: Base oil mudcement contains 600 lb/bbl Class A cement and 94.5 lb/bbl supplemental water MSF, magnesium silicofluoride PT20 is Pozzutec 20 by Master Builders ZSF is zinc silicofluoride
Efforts were continued to improve the compressive strength by using combinations of additives. Table C shows that OMC 393 had a compressive strength of 1,300 psi. This was achieved by adding 7.5 lb/bbl Pozzutec 20 and 1.75 lb/bbl cyclohexanol in a Na-2 base mix which contains 600 lb/bbl Class A cement and 107 lb/bbl additional water. In this case, the cyclohexane doubled the strength of a comparable slurry, but in two other cases it slightly decreased the strength, and in the fourth case it completely prevented set. Although the role of cyclohexanol was not clear, it may have acted as a mutual solvent such that the cement hydration reactions were improved.
TABLE C ______________________________________ Evaluation of Accelerators and Other Additives in Na-2 Mud: Hardness and Compressive Strength of Samples Cured Static at 180° F., Base OMC Contains 600 lb/bbl Class A Cement and 93 lb/bbl Water Compressive Accelerator/Additive Hardness Strength Slurry (lb/bbl) (days) (psi) (BHN) ______________________________________ OMC 248 None 3.0(64) n.s. OMC 383 PT-20, 7.5 9.9(3) 690 OMC 384 PT-20, 3.8 9.8(3) 750 OMC 385 PT-20, 7.5 9.9(5) 760 OMC 386 W, 13.3; PT-20, 7.5 9.9(5) 730 OMC 387 W, 26.6; PT-20, 7.5 9.9(5) 550 OMC 391 PT-20, 7.5; CH, 0.9 9.9(4) 750 OMC 392 PT-20, 7.5; CH, 1.8 9.9(4) 640 OMC 393 W, 13.3; PT-20, 7.5 4.4(4), 9.8(11) 1300 CH 1.75 ______________________________________ Notes: CH, cyclohexanol W, water n.s., did not set or no strength
As shown in Table D, the effects varying amounts of extra water had on hardness and compressive strength were investigated in the Na-2 mud. The extra water varied from 0 to 209 lb/bbl, while Pozzutec 20 concentration was kept constant. OMC 411 gave a compressive strength of 1,057 psi with 93 lb/bbl of extra water. This strength peak was at a W/C ratio of 35 percent, rather than at the 25 percent ratio, which theoretically can give complete hydration.
TABLE D __________________________________________________________________________ Solidification of Na-2 Mud: Effect of External Water At 180° F.; Base Mix = Na-2 + 600 lb/bbl Class A Cement BHN Added Total Additive/ Compressive Water Water Concentration Hardness/Curing Strength Slurry (lb/bbl)* (bwoc) (lb/bbl)** Time (days) (psi) __________________________________________________________________________ OMC 409 0 19.6% PT-20, 13.9 6.0(3), 8.5(4), 852 9.7(6) OMC 410 70 31.3% PT-20, 13.9 9.9(3) 925 OMC 411 93 35.1% PT-20, 13.9 10(3) 1057 OMC 412 140 43.0% PT-20, 13.9 9.9(3) 911 OMC 413 209 54.4% PT-20. 13.9 9.9(3) 727 __________________________________________________________________________ *Concentration based on mud. **Concentration based on base mix (mud + cement + water). BHN is Brinell hardness number.
Table E lists the test results of Na-4 and Na-5 (conventional low water oil mud) muds. The Na-5 mud is a 14.3 lb/gal Milpark CarboDrill with an oil-to-water ratio of 87:13. The Na-5 mud is not a "high water" mud. First of all, the base mix 449 did not set. OMC 451 made from the Na-5 mud set hard and both contained 7.5 lb/bbl Pozzutec 20. The effect of FAM on set acceleration is not as good as that of Pozzutec 20.
TABLE E ______________________________________ Solidification of Na-5 Muds at 180° F.: Na-5 Mud - Milpark's 14.3 lb/gal CarboDrill (Oil-to-Water Ratio 87:13) BHN Com- Additive/ Hardness/ pressive Base Concentration Curing Time Strength Slurry Mix (lb/bbl) (days) (psi) ______________________________________ OMC 449 449 -- 3.7(8) -- OMC 451 449 PT-20, 7.5 5.2(1), 9.2(4) 407 OMC 453 449 FAM, 4 3.7(1), 9.6(4d), -- 9.7(8) OMC 455 449 FAM, 6 5.8(1), 9.6(4), 278 9.7(8) OMC 457 449 SC*, 1.9; PT, 7.5 7.0(4), 9.8(8) <237 OMC 459 449 SC, 1.9; FAM, 4 9.7(4d) <237 ______________________________________ 449 = Na5 + 921 lb/bbl Class A cement + 335 lb/bbl water; solidsto-oil ratio = 1.8; waterto-cement = 40% *SC = SurfCote
The base slurry OMC 449 contains 921 lb/bbl Class A cement and 335 lb/bbl water in order to maintain a solids-to-oil ratio of 1.8 and a water-to-cement ratio of 40 percent. This will result in a volume increase of 180 percent based on the original mud volume. It is quite clear that a considerable amount of cement is needed to absorb the large amount of oil present in the Na-5 (conventional) oil mud. Considerable amounts of extra water are also needed to provide sufficient water for the cement hydration.
The retarding effect of SurfCote was demonstrated in a series of experiments shown in Table F. Addition of SurfCote clearly reduces the slurry yield point (lb/100 ft2) but it retards the setting. The retardation by SurfCote can be reversed by adding an accelerator such as Pozzutec 20. The OMCs treated with SurfCote did not set without adding Pozzutec 20. Table F clearly shows that the more SurfCote added, the more Pozzutec 20 is needed to offset the influence of its retardation.
TABLE F ______________________________________ Effects of Pozzutec 20 on Setting and Compressive Strength of an OMC Containing Varying Amounts of SurfCote Compressive Strength, psi SurfCote Rheology Pozzutec 20, lb/bbl (lb/bbl) YP 0 7.5 13.1 18.75 ______________________________________ 2.0 330 ns* 1107 1115 930 3.0 285 ns ns 913 977 5.0 250 ns ns ns 1008 3.0/2.0** 250 ns ns ns 1143 ______________________________________ *ns = not set **Added separately two different times
A 12-barrel batch of a 13.5 ppg Milpark's CarboDrill-HW mud (designated as Na-7 mud) was prepared. This is a "high water" content oil mud with an oil-to-water ratio of 50:50. The formulation of this mud is as follows:
______________________________________ Water 212 gallons Diesel 212 gallons NaCl 588 pounds Carbo-Tec L 11.2 gallons Lime 30 pounds Carbo-Mul 19.5 gallons Barite 3,800 pounds SurfCote 24 pounds ______________________________________
The final mud properties and retort analysis on this mud were as follows:
______________________________________ Plastic Viscosity, cp 56 Yield Point, lb/100 ft.sup.2 37 10 sec/10 min Gels, lb/100 ft.sup.2 13/15 Electrical Stability, volt 216 Oil Volume Fraction 0.39 Water Volume Fraction 0.39 Solids Volume Fraction 0.22 ______________________________________
Both the oil mud cement use and the universal fluid concept were tested in a large scale test unit which allowed mixing, pumping, filtration, and setting by using field equipment in a realistically sized simulated borehole at elevated temperatures. The filtration section of the test unit had a five-inch casing centralized (100% standoff) in a 61/2-inch borehole in a synthetic permeable core 15 feet long. Two tests, OMC-1 and OMC-2, were run using this test system.
A 12-barrel (504 gallons) batch of the above-listed mud was prepared and stabilized by stirring and pumping with high shear within the mixing unit. Portions of this mud were used for the two tests. The test slurries were batch-mixed, using this stabilized mud, with a high shear mixer (RCM cement mixing unit) just prior to their displacement into and circulation through the test model using a triplex pump.
In both tests an oil mud-cement slurry was made using a total solids-to-oil volume ratio of 1.8 and a total water-to-cement weight ratio of 0.31 (563 pounds of Class C cement and 49.3 pounds of added water per barrel of mud).
In Test OMC-1 this oil mud-cement slurry was circulated across the clean, permeable section of the model for five minutes and was then left static for five hours to filter at 100 psi pressure differential and 150° F. The filtration was then stopped and the temperature raised to 200° F. for curing.
In Test OMC-2 a universal fluid was prepared from the same base mud but with no additional water and only half of the previously used 563 pounds of cement per barrel of mud. This universal fluid was circulated across a clean permeable section of another test model and was left to filter for 18 hours at 150 psi and 150° F. Another portion of the base mud was then converted into the final oil mud-cement slurry by adding the same amounts of cement, water, and accelerators contained in the OMC-1 test. In field usage the universal fluid would have been the drilling mud and the addition of cement would have been only the differences of the components of the universal fluid and the final OMC slurry. This OMC slurry was used to displace the universal fluid from the model and to circulate across the universal fluid filter cake for several minutes. It was then left to filter at 150 psi and 150° F., forming an oil mud-cement cake on top of the universal filter cake. After the filtration it was left to cure at 250° F.
This part of the testing demonstrated that both the universal fluid and the oil mud cement slurries could be mixed, pumped, and set using field-type equipment without major operational problems.
The traditional percent "displacement efficiency" is not applicable in these tests because no normal drilling mud filter cake was formed. Building and incorporating a settable universal fluid filter cake was the major goal for the OMC-2 test.
Slurry samples collected during the displacement tests were poured in 2-inch cube molds and small shear bond molds (1.5-inch diameter by 7 inches long) and cured in a water bath at 200° F. As shown in Table G, both OMC-1 and OMC-2 were demonstrated to gain adequate compressive strengths and excellent shear bonds.
TABLE G ______________________________________ Compressive Strengths and Shear Bonds on OMC-1 and OMC-2 Samples Aged at 200° F. Average Compressive Strength (psi) Average Shear Bond (psi) Test (crushed) (shear bond mold) ______________________________________ OMC-1 895 (8 days) Not measured OMC-2 960 (7 days) 258 (7 days) ______________________________________
A slurry sample collected during the OMC-2 test was run on an ultrasonic cement analyzer (UCA). Although the ultrasonic cement analyzer indicated a strength of 534 psi, its core recovered after the ultrasonic cement analyzer test was crushed, giving a compressive strength of 1,108 psi.
Compressive strength data were obtained as checks of the effects of time and temperature on the oil mud-cement slurry and the heat aging samples. A one lab-barrel (350 ml) sample of the large test batch of the base mud was made into an oil mud-cement using the same composition as used in the displacement tests. Small vial samples of this oil mud-cement were then heat aged at 180° F. 200° F., and 210° F., leaving the main portion at room temperature. These three samples showed increased compressive strength with increased aging temperature (1,104, 1,304, and 1,385 psi, respectively, all at 2.8 days curing time).
After three days the main sample was stirred with a Hamilton Beach mixer and another vial sample taken for heat aging. After 10 days another stirred sample was taken. After 11 days a non-stirred sample and a stirred sample (OMC 701) was taken. All of these samples set hard at 180° F. giving an average Brinell compressive strength of 1,218 psi.
After 17 days, however, two stirred samples were taken, neither of which set even after 29 days at 180° F..
In some cases this time related non-setting phenomenon has been reversed by a strong mechanical shearing. In some other cases, the setting by the addition of more accelerator combined with the strong mechanical shearing has been required to initiate the test.
Each of the two test models with the solidified oil mud-cements supporting the 5-inch casing in the permeable 61/2-inch simulated borehole was cut horizontally (perpendicular to its 15-foot axis) 80 inches from the top. The lower sections (from the 80- to the 180-inch levels) were used for the hydraulic bond tests. The entire length of the model was used for the shear bond tests.
For the hydraulic bond tests, five sets of two holes each (on opposite sides of the model) were drilled at the 90-, 110-, 130-, 150-, and 180-inch levels of the bottom 100-inch-long section, each set of holes being perpendicular to the adjacent ones. One hole at each level, spiraling down around the model at 90° increments, was drilled through the 103/4-inch outside casing and almost through the permeable, synthetic formation lying just beneath. The second hole at each level was drilled through the outside casing, the permeable formation, the filter cake zone, and almost through the oil mud-cement layer (approaching but not reaching the internal casing).
Epoxy cement was then used to bond small pipe nipples, for use as pressure taps, all the way into the holes, sealing all the layers exposed by the drilling. After the epoxy had hardened a hole was drilled down the axis of each of the first set of nipples, through the remaining part of the permeable layer, and just into the filter cake layer, thus exposing the formation-filter cake junction. A hole was also drilled down the axis of each of the second set of nipples, through the remaining part of the oil mud-cement layer, and just into the inner casing surface, thus exposing the oil mud-cement casing junction.
The "hydraulic bond" at each of the formation-cake junctions and the oil mud-cement casing junctions was successively measured by injecting water through the pressure tap at a rate of four ml per minute until a pressure breakdown was noted. The maximum pressure at each tap was recorded as the hydraulic bond.
Following the hydraulic bond tests, the entire model was cut into 10-inch lengths (except for the 60-80-inch level section which was left 20 inches long). The shear bond tests were then run on each section on a hydraulic press by pressing first on the 5-inch casing to measure the oil mud-cement to pipe bond and then on the set oil mud-cement area to measure the oil mud-cement to formation bond.
As shown in Table H, both oil mud-cement systems were demonstrated to provide good bonding in the displacement models. The data on hydraulic and shear bonds indicate that the oil mud-cements can provide excellent zonal isolation in a borehole.
TABLE H ______________________________________ Average Hydraulic and Shear Bond Test Results on OMC-1 and OMC-2 Cores Hydraulic Bond (psi) Shear Bond (psi) Test No. Formation Casing Formation Casing ______________________________________ OMC-1 180 569 45 66 OMC-2 187 429 25 39 Average 184 500 35 53 ______________________________________
In the full-scale testing, the LC OMC (containing one-half the amount of the cement needed for OMC-2 and 8.4 lb/bbl Pozzutec 20) was tested as an oil-base universal fluid. This fluid was circulated in the model and left pressurized static overnight to deposit a settable filter cake in the test model. This LC OMC fluid was displaced by circulating the full OMC-2 slurry in the model at the end of the static filtration period. The entire system was then left static and pressurized to cure at elevate temperatures.
The filter cake laid down by the LC OMC hardened well. As discussed previously, the set filter cake plays a critical role in providing zonal isolation was shown in Table H.
A 5-gallon sample of the oil-base universal fluid was taken from the test batch and used for monitoring long-term rheological stability. As shown in Table I, rheological properties, slurry density, and electrical stability of this slurry were very stable for nearly 50 days. It appears that this fluid would be sufficient for drilling operations, assuming normal mud engineering care.
TABLE I __________________________________________________________________________ Monitoring of Rheological Properties of the Oil-Base Universal Fluid Slurry Properties Fann RPM Dial Reading PV YP Gels MW ES 600 300 200 100 6 3 (cp) (lb/100 ft.sup.2) (lb/gal) (volt) __________________________________________________________________________ 180 60 43 26 4 3 48 12 4 17.4 252 114 65 47 27 4 3 49 16 4 17.4 249 104 59 43 25 4 3 45 14 4 17.4 235 116 60 43 25 4 3 56 4 3 17.4 -- 102 59 43 25 4 3 53 16 3 17.4 254 105 60 44 25 4 3 54 15 3 17.4 278 106 62 45 26 5 3 44 18 3 17.4 281 107 62 45 26 5 3 45 17 3 17.4 283 108 62 44 26 5 4 46 16 4 17.4 308 117 68 50 29 5 4 49 19 4 17.4 287 110 64 48 28 5 4 56 18 4 17.4 286 120 69 52 30 5 4 51 17 4 17.4 297 118 67 50 29 5 4 51 16 4 17.4 265 123 71 58 32 5 4 52 16 4 17.4 275 120 69 52 30 5 4 52 16 4 17.4 280 121 70 52 30 5 4 51 19 4 17.4 268 __________________________________________________________________________ Notes: MW = Slurry density ES = Electrical stability Rheology measured with 10 × spring at 150° F.
Claims (10)
1. A method for cementing a well comprising:
admixing an oil mud with (a) sufficient water settable hydraulic material and water to form a slurry having a total solid-to-oil volume ratio of about 1.4 to 2.2 and a water-to-hydraulic material weight ratio of about 0.15 to 0.60, and (b) sufficient accelerator or retarder to cause the oil mud to harden and set up at a preselected time; and
displacing the slurry in the well, and allowing the oil mud to harden and set up.
2. The method of claim 1 including drilling said well with a water-in-oil emulsion mud prior to cementing said well.
3. The method of claim 1 wherein the hydraulic material is selected from the group consisting of Portland cement, fly ash, natural pozzolan, trass, tuff, blast furnace slag, and mixtures thereof.
4. The method of claim 1 wherein the accelerator is selected from the group consisting of nitrate accelerators, sodium silicate, sodium fluoride, sodium silicofluoride, magnesium silicofluoride, zinc silicofluoride, organic acids and alcohols.
5. The method of claim 1 wherein the retarder is dodecyl benzene amine sulfonate.
6. The method of claim 1 wherein the mud is used to drill the well and then is admixed to form said slurry, thereby minimizing waste and reducing mud disposal requirements.
7. The method of claim 1 wherein the water-to-hydraulic material ratio is about 0.30 to 0.35.
8. The method of claim 1 wherein the slurry is displaced to a preselected location.
9. The method of claim 1 wherein the slurry includes a salt selected from the group consisting of a sodium chloride, potassium chloride, zinc chloride, sodium nitrate and ammonium sulfate.
10. The method of claim 1 wherein the slurry includes an emulsifier selected from the group consisting of a modified tall oil fatty acid and a tall oil polyamide.
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US07/961,217 US5213160A (en) | 1991-04-26 | 1992-10-15 | Method for conversion of oil-base mud to oil mud-cement |
US08/210,637 US5382290A (en) | 1991-04-26 | 1994-04-17 | Conversion of oil-base mud to oil mud-cement |
US08/309,239 US5476144A (en) | 1992-10-15 | 1994-09-20 | Conversion of oil-base mud to oil mud-cement |
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US07/961,217 US5213160A (en) | 1991-04-26 | 1992-10-15 | Method for conversion of oil-base mud to oil mud-cement |
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US07/961,217 Expired - Lifetime US5213160A (en) | 1991-04-26 | 1992-10-15 | Method for conversion of oil-base mud to oil mud-cement |
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